Winding techniques and machines

We are proud of the diversity of winding techniques and machines we have available. This diversity allows us to manufacture in many of the standard manners and also provide coils that need to be wound in a different manner for special requirements.

The various machines we have available include:

Multi-headed machines

We have a series of multi-headed automatic winding machines that allow coils to be simultaneously wound in the same manner (making the process very quick) with little manual labour input, allowing large volumes to be made at competitive prices. These coils are terminated, wound and can be taped in some instances which results in good control and productivity.

Toroidal winding

We can wind toroidal cores and specialise in smaller inductors and chokes. There are two main methods of manufacture. The first type includes automated toroidal winding machines which count the number of turns in the winding process and ensures the correct amount of wire is used. This results in very good control and a high production speed.

When the coil’s structure will not suit automated manufacture, usually due to trying to fit a large amount of wire turns through a core’s small inside diameter, a second method is employed. This is called pull winding and uses a pneumatically powered hook to pull the wire through the centre of the core. This method allows a wide degree of flexibility in the size of the core and wire used to make a coil.

Specialised forms of winding

AGW is capable of other more specialised forms of manufacture. The following techniques and machines are focused on the ability to produce complicated windings rather than being able to carry out operations quickly.

Wave windingWave winding is a traditional method that produces coils for RF applications, in a manner that reduces the coil’s inter-winding capacitance.

Copper strip windingWe have made copper winding machines that have the control and strength to wind copper strip around a designated bobbin. Modern ferrite allows larger currents to be used in the coil without saturation occurring. This means that a conductive material is required that will carry the current, but will not be influenced by the skin effect at higher frequencies. The lesser thickness of the copper strip against circular wire gives this advantage.

Multi-directional windingWe developed a multi-directional winding machine and tooling in order to produce a coil in a unique manner.